CN112730603B - Method for improving crack depth detection range of eddy current detection and system device thereof - Google Patents
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- G01N27/90—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws using eddy currents
- G01N27/9046—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws using eddy currents by analysing electrical signals
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Abstract
The invention relates to a method for improving the detection range of crack depth in eddy current detection and a system device thereof, which are used for scanning defects such as cracks on the surface of metal.
Description
Technical Field
The invention relates to the technical field of electromagnetic nondestructive testing, in particular to an eddy current nondestructive testing sensor device for metal materials, and particularly relates to a method for improving the detection range of crack depth in eddy current testing and a system device thereof.
Background
The application of the eddy current inspection method, which is one of five conventional nondestructive inspection methods, is increasingly widely applied to the fields of aerospace, nuclear industry, ships, railways, electric power, petrochemical industry and the like as the technology of the eddy current inspection method is advanced. The rapid assessment of the depth of cracks in the metal surface by eddy current methods is one of its advantages. However, the electronic dynamic range of the eddy current instrument is limited, and the frequency application range of the eddy current probe is limited, so that in practice, parameters such as frequency, gain and the like of the instrument are required to be replaced according to different crack depths, and meanwhile, the probe is required to be replaced while the frequency is changed, so that the optimal quantitative crack depth detection effect is achieved. For example, the railway turnout has a wide coverage range from zero to fracture, and the depth range of the crack to be evaluated is wide according to the railway traffic detection requirement. Thus, the operation method of detection in the prior art is troublesome.
Aiming at the problems of the defects, the invention adopts the following technical proposal for improvement.
Disclosure of Invention
The invention aims to provide a method for improving the crack depth detection range of eddy current detection and a system device thereof, and the disclosed technical scheme is as follows:
The method for improving the crack depth detection range of the eddy current detection is characterized in that an eddy current detection sensor is arranged as a spiral coil which is concentrically arranged, the spiral coil is divided into a plurality of sub-coils with different frequency sections, each section of frequency is connected with a corresponding connection node, the opening and closing of each node are switched through an analog switch, different excitation frequencies are switched, and the method is used for detecting the defects of cracks with different depths of a metal material, and the like, and specifically comprises the following steps:
a. detecting frequency band setting: setting different excitation frequencies of sine wave excitation electric signals according to the detection requirements of the detected object and according to different divisions of the turn number length of the eddy current detection coil;
b. Analog switch setting: c, setting the switching-on and switching-off sequence of the analog switch, and matching the electric signals with different excitation frequencies set in the step a with corresponding eddy current detection coils;
c. Scanning sequence selection: b, selecting a scanning sequence of eddy current detection according to the on-off sequence of the analog switch set in the step b;
d. and (3) eddy current scanning detection: scanning eddy current detection is carried out on the detected object, and the detection data result is transmitted to an eddy current detection analysis instrument;
e. And (3) analyzing data of each frequency segment: combining the detection data of each frequency segment, and carrying out fusion analysis to judge the information such as the depth position of the defects such as the metal cracks;
f. And (3) data storage display: the analysis data are stored in an eddy current testing and analyzing instrument and displayed on a display screen.
The eddy current detection sensor coil is divided into at least two frequency section nodes with different lengths, the frequency is set to be the highest frequency point on the node closest to the center point, and the frequencies are sequentially arranged to be lower and lower outwards.
The spiral coils of the concentric arrangement of the eddy current sensor are arranged in a tower-shaped spiral arrangement with the center points protruding out of the spiral plane and protruding out of the spiral plane, the frequency setting in the step a is further based on the lift-off value formed by the protruding height of the tower-shaped spiral coils out of the spiral plane, and the corresponding lift-off value is used as reference data for judging the depth position of the defect in the step e.
In addition, the eddy current sensor coil can be further divided into two frequency segments with different lengths, the middle node f1 is a high-frequency point, the outer end node f0 is a low-frequency point, the center point is grounded, the frequency setting is combined with the spiral coil to set a lifting value formed by the tower-shaped spiral arrangement of the spiral coil protruding from the spiral plane at the center point, the middle node f1 is a defect of detecting the position with the depth of less than or equal to 1.0mm from the detection surface, and the outer end node f0 is a defect of detecting the position with the depth of more than or equal to 1.0mm from the detection surface. After the fixed lift-off value formed by the spiral arrangement of the tower-shaped plane, different frequencies of the middle node f1 can be set to just detect defects at three fixed point positions with depths equal to 0.1mm, 0.5mm and 1.0mm from the detection surface, different frequencies of the outer end node f0 can be set to just detect defects at three fixed point positions with depths equal to 1.0mm, 3.0mm and 5.0mm from the detection surface, and the eddy current detection sensor can detect the metal thickness of 6.0 mm in one scanning.
The invention also discloses a detection system for improving the detection range of the crack depth of the eddy current detection, which comprises a detection signal input module (61), a detection data output module (62) and a multi-node spiral coil type eddy current sensor module (63), wherein the detection signal input module (61) comprises a frequency value setting unit (611), a frequency switching sequence setting unit (612), a frequency setting unit (613) corresponding to each node and an analog switch switching unit (614), the detection data output module (62) comprises a detection data analysis unit (621) of each frequency section, a data analysis unit (622) of each frequency section in fusion, a position unit (623) of the determined defect depth and a data recording display unit (624), and is characterized in that the spiral coil of the multi-node spiral coil type eddy current sensor module (63) is divided into a plurality of different frequency section sub-coils, each section frequency is connected with a corresponding connection node, and the opening and closing of each node are switched through an analog switch and the different excitation frequencies are switched for detecting the defects such as cracks of different depths of metal materials.
The multi-node spiral coil type eddy current sensor module (63) is at least provided with more than two nodes with different frequency sections, the frequency is set to be the highest frequency point on the node closest to the center point of the spiral coil, and the frequencies are sequentially arranged to be lower and lower outwards.
In addition, the spiral coil type eddy current sensor module (63) is provided with two different frequency points of an intermediate node f1 and an outer end node f0, the frequency value and the lift-off value are combined, the intermediate node f1 is provided with a defect of a position with a depth of less than or equal to 1.0mm from a detection surface, and the outer end node f0 is provided with a defect of a position with a depth of more than or equal to 1.0mm from the detection surface.
The invention also discloses a detection device for improving the detection range of the crack depth of the eddy current detection, which is used for scanning defects such as cracks on the metal surface, and is characterized in that the eddy current detection sensor device is arranged as a spiral coil which is concentrically arranged, the spiral coil is divided into a plurality of sub-coils with different frequency sections, each section of frequency is connected with a corresponding connection node, and the opening and closing of each node are switched through an analog switch, and different excitation frequencies are switched.
The spiral coil of the eddy current sensor is divided into at least two frequency section nodes with different lengths, the frequency is set to be the highest frequency point on the node closest to the center point, and the frequencies are sequentially arranged to be lower and lower outwards.
The spiral coils of the concentric arrangement of the eddy current sensor are arranged in a tower-shaped spiral shape with the central points protruding out of the spiral plane and protruding out of the spiral plane, and the heights of the tower-shaped spiral coils protruding out of the spiral plane form a fixed lift-off value.
According to the technical scheme, the invention has the following beneficial effects: 1. the eddy current detection sensor adopts a method of combining a structure of leading-out nodes in a spiral coil with a high-frequency analog change-over switch excitation frequency, and realizes detection of the depth position information of the metal surface crack by utilizing the characteristic that the multi-frequency eddy current sensor has different sensitivity and penetration depths to different depths. 2. The spiral coil of the eddy current detection sensor is arranged to be a tower-type spiral structure with the center protruding, so that a fixed lift-off effect is formed, and the detection depth position is adjusted more accurately.
Drawings
FIG. 1 is a schematic diagram of an eddy current sensor connected to an analog switch according to a preferred embodiment of the invention;
FIG. 2 is a schematic diagram of a multi-node spiral coil of an eddy current sensor in accordance with a preferred embodiment of the invention;
FIG. 3 is a schematic diagram of the spiral coil of the eddy current sensor according to the preferred embodiment of the invention in two stages;
FIG. 4 is a schematic view of the spiral coil of the eddy current sensor according to the preferred embodiment of the invention in a planar spiral shape;
FIG. 5 is a schematic view of a spiral coil of an eddy current sensor according to a preferred embodiment of the invention in a form of a tower spiral;
FIG. 6 is a flow chart of a method according to a preferred embodiment of the present invention;
FIG. 7 is a schematic diagram of a system module according to a preferred embodiment of the present invention;
FIG. 8 is a schematic diagram showing the use state of a test flat sample according to the preferred embodiment of the present invention;
FIG. 9 is a schematic view of the present invention for detecting the usage status of the rail tread.
Detailed Description
The invention will be further described with reference to the drawings and detailed description.
As shown in fig. 1 to 6, a method for increasing the detection range of crack depth in eddy current detection is characterized in that an eddy current detection sensor is provided as a spiral coil 1 which is concentrically arranged, the spiral coil 1 is divided into a plurality of sub-coils with different frequency segments, each segment is connected with a corresponding connection node f0-f5, the opening and closing of each node are switched through an analog switch, and different excitation frequencies are switched, so as to detect defects such as cracks with different depths of a metal material, as shown in fig. 6, and the specific steps are as follows:
a. detecting frequency band setting: setting different excitation frequencies of sine wave excitation electric signals according to the detection requirements of the detected object and according to different divisions of the turn number length of the eddy current detection coil;
b. Analog switch setting: c, setting the switching-on and switching-off sequence of the analog switch, and matching the electric signals with different excitation frequencies set in the step a with corresponding eddy current detection coils;
c. Scanning sequence selection: b, selecting a scanning sequence of eddy current detection according to the on-off sequence of the analog switch set in the step b;
d. and (3) eddy current scanning detection: scanning eddy current detection is carried out on the detected object, and the detection data result is transmitted to an eddy current detection analysis instrument;
e. And (3) analyzing data of each frequency segment: combining the detection data of each frequency segment, and carrying out fusion analysis to judge the information such as the depth position of the defects such as the metal cracks;
f. And (3) data storage display: the analysis data are stored in an eddy current testing and analyzing instrument and displayed on a display screen.
The eddy current detection sensor coil is divided into at least two frequency segment nodes with different lengths, the frequency is set to be the highest frequency point on a node f1 closest to the center point, and the frequencies are sequentially arranged to be lower and lower outwards.
The spiral coils of the concentric arrangement of the eddy current sensor are arranged in a tower-shaped spiral arrangement with the center points protruding out of the spiral plane and protruding out of the spiral plane, the frequency setting in the step a is further based on the lift-off value formed by the protruding height of the tower-shaped spiral coils out of the spiral plane, and the corresponding lift-off value is used as reference data for judging the depth position of the defect in the step e.
In addition, the eddy current sensor coil can be further divided into two frequency segments with different lengths, the middle node f1 is a high-frequency point, the outer end node f0 is a low-frequency point, the center point is grounded, the frequency setting is combined with the spiral coil to set a lifting value formed by the tower-shaped spiral arrangement of the spiral coil protruding from the spiral plane at the center point, the middle node f1 is a defect of detecting the position with the depth of less than or equal to 1.0mm from the detection surface, and the outer end node f0 is a defect of detecting the position with the depth of more than or equal to 1.0mm from the detection surface. After the fixed lift-off value formed by the spiral arrangement of the tower-shaped plane, different frequencies of the middle node f1 can be set to just detect defects at three fixed point positions with depths of 0.1mm, 0.5mm and 1.0mm from a detection surface, different frequencies of the outer end node f0 can be set to just detect defects at three fixed point positions with depths of 1.0mm, 3.0mm and 5.0mm from the detection surface, as shown in fig. 8, in the detected object metal material 3, an eddy current detection sensor can switch the opening and closing of the outer end node f0 and the middle node f1 of two nodes through an analog switch, and switch different frequencies during scanning detection on the two nodes, and the middle node f1 detects the defects at the positions with the depths of 0-1mm from the detection surface, and the outer end node f0 is at the positions with the depths of 1-5mm from the detection surface. As shown in fig. 9, when scanning and detecting the railway rail 4, the eddy current detecting sensor may be further provided as a plurality of tower-shaped spiral coils in array, so as to realize one scanning and detect defect information of the rail surface depth of 5mm, and the detected signal is transmitted to the detecting and analyzing instrument 5 through the lead wire 51.
As shown in fig. 7, the present invention further discloses a detection system for increasing the detection range of the crack depth in the eddy current detection, which includes a detection signal input module 61, a detection data output module 62 and a multi-node spiral coil type eddy current sensor module 63, wherein the detection signal input module 61 includes a frequency value setting unit 611, a frequency switching sequence setting unit 612, a frequency setting unit 613 corresponding to each node, and an analog switch switching unit 614, and the detection data output module 62 includes a detection data analysis unit 621 of each frequency segment, a data analysis unit 622 of each frequency segment, a position determining defect depth unit 623, and a data recording display unit 624.
Wherein, the multi-node spiral coil type eddy current sensor module 63 is provided with at least two nodes with different frequency ranges, the frequency is set to be the highest frequency point on the node closest to the center point of the spiral coil, and the frequencies are sequentially arranged to be lower and lower outwards.
In addition, the spiral coil type eddy current sensor module 63 is provided as two different frequency points of the intermediate node f1 and the outer end node f0, the intermediate node f1 is provided to detect a defect at a position of 1.0mm or less from the detection surface depth, and the outer end node f0 is provided to detect a defect at a position of 1.0mm or more from the detection surface depth, in combination with the frequency value and the lift-off value.
As shown in fig. 1,2 and 3, the invention also discloses a detection device for improving the detection range of crack depth in eddy current detection, which is used for scanning defects such as cracks on the metal surface, and is characterized in that the eddy current detection sensor device is provided with spiral coils 1 which are concentrically arranged, the center of each spiral coil 1 is a grounding end 2, the middle of each spiral coil is divided into a plurality of sub-coils with different frequency sections, each section of frequency is connected with a corresponding connection node f0-f5, the opening and the closing of each node are switched through an analog switch 11, and the connection is connected with a multi-frequency sine wave excitation circuit 12, so that different excitation frequencies are switched.
The spiral coil 1 of the eddy current sensor is divided into at least two frequency band nodes with different lengths, the frequency is set to be the highest frequency point on the node closest to the center point, and the frequencies are sequentially arranged to be lower and lower outwards.
As shown in fig. 4 and 5, the spiral coils 1 of the eddy current sensor concentrically arranged may be on the same plane as in fig. 4. It is also possible to arrange, as shown in fig. 5, that the spiral coil 1 of the eddy current sensor concentrically arranged is arranged in a tower-shaped spiral arrangement with its center point protruding from the spiral plane, the height of the tower-shaped spiral coil 1 protruding from the spiral plane forming a fixed lift-off value.
The above is one embodiment of the present invention. In addition, it should be noted that all equivalent or simple changes of the structure, features and principles described in this patent conception are included in the scope of the present patent.
Claims (8)
1. The method for improving the crack depth detection range of the eddy current detection is characterized in that an eddy current detection sensor is arranged as a spiral coil which is concentrically arranged, the spiral coil is divided into a plurality of sub-coils with different frequency sections, each section of frequency is connected with a corresponding connection node, the opening and closing of each node are switched through an analog switch, and different excitation frequencies are switched, so that the crack defects with different depths of a metal material are detected, and the method comprises the following specific steps:
a. detecting frequency band setting: setting different excitation frequencies of sine wave excitation electric signals according to the detection requirements of the detected object and according to different divisions of the turn number length of the eddy current detection coil;
b. Analog switch setting: c, setting the switching-on and switching-off sequence of the analog switch, and matching the electric signals with different excitation frequencies set in the step a with corresponding eddy current detection coils;
c, selecting a scanning sequence: b, selecting a scanning sequence of eddy current detection according to the on-off sequence of the analog switch set in the step b;
d, eddy current scanning detection: scanning eddy current detection is carried out on the detected object, and the detection data result is transmitted to an eddy current detection analysis instrument;
e, analyzing data of each frequency segment: combining the detection data of each frequency segment, and carrying out fusion analysis to judge the depth position information of the metal crack defect;
f, data storage and display: storing analysis data in an eddy current testing and analyzing instrument and displaying the analysis data on a display screen;
the spiral coils concentrically arranged in the eddy current sensor are arranged in a tower-shaped spiral shape with the center points protruding out of the spiral plane and protruding out of the spiral plane, the frequency setting in the step a is further based on the lift-off value formed by the protruding height of the tower-shaped spiral coils out of the spiral plane, and the corresponding lift-off value is used as reference data for judging the depth position of the defect in the step e.
2. The method for increasing crack depth detection range in eddy current inspection according to claim 1, wherein the eddy current inspection sensor coil is divided into at least two frequency segment nodes of different lengths, the frequency is set to be the highest frequency point on the node closest to the center point, and the frequencies are sequentially set to be sequentially lower and lower.
3. The method for increasing crack depth detection range for eddy current inspection according to claim 1 or 2, wherein the eddy current inspection sensor coil is divided into two frequency segments of different lengths, the middle node f1 is a high frequency point, the outer end node f0 is a low frequency point, the center point is grounded, the frequency setting is combined with the spiral coil to set a lift-off value formed by a tower-shaped spiral arrangement of the center point protruding from the spiral plane and protruding from the spiral plane, the middle node f1 is a defect for detecting a position with a depth of less than or equal to 1.0 mm from the inspection surface, and the outer end node f0 is a defect for detecting a position with a depth of 1.0 mm or more from the inspection surface.
4. The detection system for improving the detection range of the crack depth of the eddy current detection comprises a detection signal input module (61), a detection data output module (62) and a multi-node spiral coil type eddy current sensor module (63), wherein the detection signal input module (61) comprises a frequency value setting unit (611), a frequency switching sequence setting unit (612), a frequency setting unit (613) corresponding to each node and an analog switch switching unit (614), the detection data output module (62) comprises a frequency section detection data analysis unit (621), a fusion frequency section data analysis unit (622), a defect depth judgment position unit (623) and a data recording display unit (624), and is characterized in that a spiral coil of the multi-node spiral coil type eddy current sensor module (63) is divided into a plurality of different frequency section sub-coils, each section of frequency is connected with a corresponding connection node, and the opening and closing of each node are switched through an analog switch and different excitation frequencies are switched for detecting crack defects of different depths of metal materials;
The spiral coils of the multi-node spiral coil type eddy current sensor module are concentrically arranged, the spiral coils are arranged in a tower-shaped spiral shape with central points protruding out of the spiral plane and protruding out of the spiral plane, and the height of the tower-shaped spiral coils protruding out of the spiral plane forms a fixed lift-off value.
5. The system according to claim 4, wherein the multi-node spiral coil type eddy current sensor module (63) is provided with at least two nodes with different frequency ranges, the frequency is set to be the highest frequency point on the node closest to the center point of the spiral coil, and the frequencies are sequentially set to be sequentially lower and lower.
6. The inspection system for improving the inspection range of crack depth in eddy current inspection according to claim 5, wherein the spiral coil type eddy current sensor module (63) is configured to detect defects at a position of 1.0 mm or less from the inspection surface by combining the frequency value with the lift-off value at two different frequency points of the intermediate node f1 and the outer end node f0, and the outer end node f0 is configured to detect defects at a position of 1.0 mm or more from the inspection surface.
7. The detection device is characterized in that the eddy current detection sensor device is arranged as a spiral coil which is concentrically arranged, the spiral coil is divided into a plurality of sub-coils with different frequency sections, each section of frequency is connected with a corresponding connection node, and the opening and closing of each node and the switching of different excitation frequencies are switched through an analog switch;
The spiral coils concentrically arranged in the eddy current sensor are arranged in a tower-shaped spiral shape with central points protruding out of the spiral plane and protruding out of the spiral plane, and the heights of the tower-shaped spiral coils protruding out of the spiral plane form a fixed lift-off value.
8. The device for increasing crack depth detection range in eddy current inspection according to claim 7, wherein the spiral coil of the eddy current inspection sensor is divided into at least two frequency band nodes of different lengths, the frequency is set to be the highest frequency point on the node closest to the center point, and the frequencies are sequentially set to be sequentially lower.
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| US5068608A (en) * | 1989-10-30 | 1991-11-26 | Westinghouse Electric Corp. | Multiple coil eddy current probe system and method for determining the length of a discontinuity |
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| CN109406621B (en) * | 2018-12-30 | 2023-05-26 | 北方民族大学 | Double-frequency uniform vortex probe and deep crack mixing detection signal extraction technology |
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| US4855677A (en) * | 1988-03-11 | 1989-08-08 | Westinghouse Electric Corp. | Multiple coil eddy current probe and method of flaw detection |
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